Externally and internally shielded double-layered flat cable assembly

Abstract

A double-layered flat electrical signal assembly comprising a shielded insulated flat cable on each side of a perforated separator material which may be conductive metal or non-metal. Controlled impedance signal transmission through high density insulation displacement connectors to PCB's.

I claim: 
     
       1. A double-layered flat electrical signal assembly comprising two flat electrical signal cables located on each side of a sheet of perforated conductive metal separator material, each said flat cable comprising a multiplicity of insulated electrical signal conductors arranged in a parallel coplanar configuration at a specified distance apart, said conductors each being surrounded by low dielectric constant insulation and a web of insulation located between said conductors, said insulated conductors covered as a unit by a conductive metal shield on at least one side of said cable, and each said shield covered by an insulative outer jacket. 
     
     
       2. A cable of claim 1 wherein said sheet of perforated conductive metal separator material is a mesh. 
     
     
       3. A process for manufacturing a double-layered flat electrical signal assembly, comprising the steps: (a) surrounding each conductor of two multiple sets of electrical signal conductors with a low-dielectric constant insulation;   (b) passing two said sets of conductors, a low-dielectric constant cabling tape on each side of each set of conductors, and a sheet of conductive or non-conductive separator material located between each set of conductors together into the nip of a first set of heated compression rollers;   (c) passing the flat cable issuing from said rollers together with a sheet of formed conductive shielding located on each side of said cable and one or more conductive drain wires into the nip of a second set of compression rollers;   (d) passing the cable issuing from said second set of compression rollers into an edge trim device;   (e) passing the cable issuing from said edge trim device into a jacket extruder;   (f) extruding a protective polymeric outer jacket onto said cable issuing from said edge trim device; and   (g) taking up said assembly on a takeup spool.   
     
     
       4. A double-layered flat electrical signal assembly manufactured by the process of claim 3.